Apparatus for electrically connecting a flexible circuit to a receiver

ABSTRACT

An electrical connector assembly combination includes a receptacle with a plurality of electrical contacts, and a connector device with housing configured to accept and retaining a terminal end of a flexible assembly comprising one or more flexible electrical conductors. The terminal end of the flexible assembly includes one or more electrical contacts. The connector device is capable of being reversibly coupled and interlocked with the receptacle such that each of the electrical contacts in the receptacle is electrically connected to a corresponding contact at the terminal end of the flexible assembly in a secure, removable and non-permanent manner.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/219,454, filed on Mar. 19, 2014, which is a continuation-in-part ofU.S. patent application Ser. No. 13/760,574, filed on Feb. 6, 2013, nowU.S. Pat. No. 8,821,167, which claims priority from U.S. ProvisionalPatent Application Ser. No. 61/653,813, filed on May 31, 2012, entitled“Apparatus for Electrically Connecting a Flexible Circuit to aReceiver,” the specifications of which are incorporated herein byreference in their entirety.

FIELD OF THE INVENTION

The invention relates generally to electrical connection assemblies and,more particularly, to electrical connection assemblies for coupling aflexible electrical conductor to a rigid assembly, such as a circuitboard.

BACKGROUND OF THE INVENTION

Sophisticated electrical and electronic components are frequentlydisposed proximate to high vibration equipment, such as aircraft androcket engines. Because of the narrow confines wherein such componentsare typically disposed, interconnecting such components often employsthe use of flexible electrical conductors (“flexible assemblies”).

The prior art methods of attaching a flexible assembly to a rigidassembly (such as a circuit board) usually employ some form of permanentattachment, such as methods wherein the flexible assembly is soldered tothe rigid assembly.

Problems arise in such prior art methods when the attachment between theflexible assembly and the rigid assembly needs to be disengaged (torepair the rigid assembly, or for other relevant purposes requiringdisassembly or unmating of the assembly). Such activities cannot easily(if at all) be performed in the field, and, in most cases, require thecomplete replacement of both flexible assembly and rigid assembly. Suchcomplete replacement of both assemblies is awkward, time-consuming andexpensive.

Accordingly, there is a need for a method of attaching a flexibleassembly to a rigid assembly which does not involve the aforementionedproblems in the prior art.

SUMMARY OF THE INVENTION

An apparatus for electrically connecting a flexible electrical assemblywith conductors to a receiver is presented. One or more embodiments ofinvention comprise an electrical assembly combination comprising areceiver with a plurality of electrical contacts. The receiver may bemounted on a rigid assembly, e.g. a circuit board, and the electricalcontacts are connected to electrical circuits/elements on the rigidassembly. The receiver may also include an insulator assembly toelectrically isolate the electrical contacts from one another.

One or more embodiments of the invention further comprise a connectordevice configured to retain at least one terminal end of a flexibleconductor assembly (hereby also referred to as “flexible assembly”). Theterminal end of the flexible conductor assembly also includes one ormore electrical contacts to the conductors in the flexible assembly. Theconnector device is configured to be reversibly coupled to the receiversuch that the electrical contacts in receiver are electrically connectedto the electrical contacts at the terminal end of the flexible conductorassembly in a removable, non-permanent manner. In one or moreembodiments, coupling of the connector to the receptacle is preferablyby a twist and lock.

An objective of this invention is an apparatus specifically forelectrically and mechanically connecting a rigid, semi-rigid and/orflexible circuit/conductor assembly using replaceable and repairableconductive elements found within the flexible circuit directly to areceiver termination point, wherein the termination point has aplurality of conductive elements located within the receiver in a mannerthat: a) a connector device houses the flexible circuit and flexiblecircuit elements and the receiver contains the receiver conductiveelements and; b) the connector device may be non-destructivelydisconnected from the receiver and; c) some or all of the conductiveelements may be replaceable and/or repairable within the apparatus and;d) the flexible circuit conductive elements may be non-destructivelyengaged and/or disengaged with the receiver conductive elements and; e)physically isolates the connected end of the flexible circuit and matinginterface of the receiver termination point from both foreigncontaminates and stray electrical transients and; f) maintains bothelectrical connectivity and contaminant protection when subject toextreme environments including, but not limited to, mechanical, thermal,electrical, and chemical stresses.

A feature of preferred embodiments of this combination includes anenclosure for accepting and retaining the flexible circuit mating end(i.e. terminal end) such that the flexible circuit may benon-destructively removed from the enclosure, and positions the flexiblecircuit within the enclosure in a manner that allows the electricallyconductive elements within the flexible circuit to be exposed to theconductive elements within the receiver in order to make physicalcontact and become electrically interconnected with the flexible circuitconductive elements in a non-permanent form that would allow theflexible circuit conductive elements to become disengaged from thereceiver conductive elements without causing damage to either theflexible circuit conductive elements or the receiver conductiveelements.

In One or more embodiments, the combination includes a plurality ofconductive elements within both the flexible circuit and receiver,wherein the flexible circuit conductive elements and receiver conductiveelements may physically couple in a manner that creates an electricalconnection between the two mated elements, and the mated elements may bedisconnected from each other without causing damage to either of theconductive elements, and the conductive elements may be removed fromtheir retention feature within their respective housing without causingdamage to either the conductive element or retention feature or housing,and may be configured using existing solderless connection methods,including but not limited to: pin-socket mating systems, spring probesystems and compressive contact systems.

One or more embodiments of the invention may further include a physicalseal or barrier between both the enclosure for the flexible circuit andthe receiver that prevents any undesirable foreign elements, includingboth physical contaminants and stray electrical transients, fromentering the engagement area between the flexible circuit conductiveelements and the receiver conductive elements.

One or more embodiments of the invention may further include aninterlocking mechanism between both the flexible circuit enclosuredevice (i.e. connector device) and the receiver that upon fullengagement of the interlocking mechanism: a) the flexible circuitconductive elements are electrically connected with the receiverconductive elements and; b) the seal between the flexible circuitenclosure and receiver prevents foreign contamination, including bothphysical contaminants and stray electrical transients.

In one or more embodiments of the invention, the interlocking mechanismprevents the enclosure from disengaging from the receiver duringoperation of the apparatus in harsh environments, e.g. under extremevibration.

The combination may further incorporate active and passive accessoriesand components, such as signal filters, signal indicators and powerregulators. The apparatus may further incorporate design features, suchas “scoop-proof” components or keying features to ensure properalignment of conductive elements.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdescription, appended claims and accompanying drawings where:

FIG. 1 is a perspective view of an electrical assembly combination inaccordance with one or more embodiments of the present invention;

FIG. 2 is perspective view of the connector device separated from thereceiver in accordance with one or more embodiments of the presentinvention;

FIG. 3 is a fully exploded perspective view of the electrical assemblycombination in accordance with one or more embodiments of the presentinvention; and

FIG. 4 is a cross-sectional view of the electrical assembly combinationillustrated in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

An apparatus for electrically connecting at least one flexibleelectrical assembly with conductors to a receiver will now be described.In the following exemplary description numerous specific details are setforth in order to provide a more thorough understanding of embodimentsof the invention. It will be apparent, however, to an artisan ofordinary skill that the present invention may be practiced withoutincorporating all aspects of the specific details described herein.Furthermore, although steps or processes are set forth in an exemplaryorder to provide an understanding of one or more systems and methods,the exemplary order is not meant to be limiting. One of ordinary skillin the art would recognize that the steps or processes may be performedin a different order, and that one or more steps or processes may beperformed simultaneously or in multiple process flows without departingfrom the spirit or the scope of the invention. In other instances,specific features, quantities, or measurements well known to those ofordinary skill in the art have not been described in detail so as not toobscure the invention. Readers should note that although examples of theinvention are set forth herein, the claims, and the full scope of anyequivalents, are what define the metes and bounds of the invention.

For a better understanding of the disclosed embodiment, its operatingadvantages, and the specified object attained by its uses, referenceshould be made to the accompanying drawings and descriptive matter inwhich there are illustrated exemplary disclosed embodiments. Thedisclosed embodiments are not intended to be limited to the specificforms set forth herein. It is understood that various omissions andsubstitutions of equivalents are contemplated as circumstances maysuggest or render expedient, but these are intended to cover theapplication or implementation.

The term “first”, “second” and the like, herein do not denote any order,quantity or importance, but rather are used to distinguish one elementfrom another, and the terms “a” and “an” herein do not denote alimitation of quantity, but rather denote the presence of at least oneof the referenced item.

One or more embodiments of the invention provide an electrical assemblycombination for electrically/electronically connecting a flexiblecircuit (e.g. cable, flat cable, etc.) to a receiver. The electricalassembly combination apparatus comprises a connector configured tocouple to a receiver. The connector comprises an enclosure for aterminal end of a flexible circuit configured such that the flexiblecircuit may be non-destructively removed from the enclosure. Theflexible circuit is contained in the enclosure such that the conductiveelements at the terminal end are exposed at an end where the connectoris coupled with the receiver. The conductive elements arenon-permanently electrically connected to conductive elements in theflexible circuit. The conductive elements consist of electricallyconductive materials physically configured to engaged and disengage in anondestructive manner by conventional or nonconventional means. Theconnector enclosure may also be configured with a first half of aninterlocking mechanism, e.g. a connector interlocking cap.

In one or more embodiments, the receiver may be mounted on a rigidassembly, e.g. a circuit board. The receiver includes a receptacle andone or more the electrical contacts inside that are connected toelectrical circuits/elements on the rigid assembly. The receptacle isconfigured with a second half of the interlocking mechanism, i.e. areceiver interlocking member. The receiver may also include an insulatorassembly to electrically isolate its electrical contacts from oneanother.

One or more embodiments of the invention further comprise seals betweenthe connector device and receiver to prevent contamination from foreignelements, including both physical contaminants and stray electricaltransients. The seals may comprise components in the connector device,the receiver, or both.

The interlocking mechanism typically comprises features that ensuresecure engagement between the conductive elements in the flexiblecircuit and the conductive elements in the receiver.

In one or more embodiments of the invention, when coupled, theinterlocking mechanism prevents the connector from disengaging from thereceiver and to maintain electrical contact during operation of theapparatus in extreme environments, e.g. under extreme vibration.

One or more embodiments of the invention may further include aninterlocking mechanism between both the flexible circuit enclosuredevice (i.e. connector device) and the receiver that upon fullengagement of the interlocking mechanism: a) the flexible circuitconductive elements are electrically connected with the receiverconductive elements and; b) the flexible circuit enclosure and receiverare sealed as one unit to prevent foreign contamination, including bothphysical contaminants and stray electrical transients.

A detailed description of the specific components and optionalcomponents of the apparatus for electrically connecting a flexibleelectrical assembly with conductors to a receiver in accordance with anembodiment of the present invention will be described using theillustrations of FIGS. 1 to 4.

One embodiment of the electrical assembly combination 10 is illustratedin FIG. 1. FIG. 2 illustrates the receiver and connector deviceindividually. FIG. 3 is a fully exploded view of the electrical assemblycombination, and FIG. 4 is a cross-sectional view of the electricalassembly combination, showing how the principal component parts areassembled.

An embodiment of the invention comprises an electrical assemblycombination 10 useful in connecting a flexible assembly 22 to a rigidassembly 12. The invention comprises a receiver 13 and a connectordevice (i.e. plug) 14.

The receiver 13 comprises a receiver housing 16, receiver interlockingmember or receptacle 17 and one or more of receiver housing electricalcontacts 18. The receiver 13 is configured to be coupled to the rigidassembly 12. Coupling may be by gluing, with nuts and bolts (not shown)through a plurality of holes on the receiver housing, e.g. 19, or othermeans.

In one or more embodiments, the rigid assembly 12 is a circuit board,although the invention can also be used with other types of rigidassemblies.

The receiver 13 comprises one or more receiver housing electricalcontacts 18. Receiver housing electrical contacts 18 may be configuredas part of the receiver assembly 13, or separate and replaceable, etc.As illustrated, each receiver housing electrical contact 18 may beseparable and replaceable and configured to mechanically andelectrically connect with electrical contact slots 23 on the rigidassembly 12.

In one or more embodiments, the Receiver interlocking receptacle 17 isconfigured as one half of an interlocking mechanism and is configured tomechanically mate (i.e. couple) with a second half of the interlockingmechanism located on the connector device 14. Mating or coupling ofconnector 14 to receiver 13 via the interlocking mechanism may beaccomplished through a twist-to-lock mechanism, for example. Those ofskill in the art would appreciate that other types of interlockingmechanisms may be used without deviating from the spirit of theinvention. For instance, nuts and bolts, push-twist-and-lock,pull-twist-and-lock, etc. are all possible types of interlockingmechanisms.

In one or more embodiments, the receiver 13 further comprises aninsulator assembly 28. Insulator assembly is configured to provideelectrical isolation between members of the one or more of receiverhousing electrical contacts 18 and also for isolating the one or morereceiver housing electrical contacts 18 from any conducting elements inthe receiver housing. The insulator assembly is used to mechanicallyretain, electronically isolate and insulate the receiver housingelectrical contacts 18. Insulator assembly 28 can be constructed ofglass-filled epoxy resin or other non-conductive materials.

In one or more embodiments, the receiver 13 further comprises anoptional sealing component 29 for sealing the receiver housing 16 to theconnector device 14.

The optional sealing component 29 provides a seal to protect the spacebetween the various components of the electrical assembly combination toprevent contamination from foreign entities. Such seal acts in a mannerthat prevents any undesirable foreign entities from entering theengagement area between the flexible assembly electrical contacts andthe receiver housing electrical contacts. Sealing component 29 could bea grommet (e.g. rubber) and/or gasket, washer, etc. and is configured toserve an array of functions, such as, but not limited to, environmentalsealing, EMI/EMC bonding, vibration dampening and air volume reduction.

The connector device 14 comprises a connector housing 20 configured toaccept and retain at least one terminal end of a flexible assembly 22.The terminal end of flexible assembly 22 includes one or more flexibleassembly electrical contacts 24. Flexible assembly electrical contacts24 may be configured as part of the terminal end of flexible assembly22, or separate and replaceable, etc. As illustrated, each flexibleassembly electrical contact 24 may be separable and replaceable andconfigured to mechanically and electrically connect with electricalcontact slots 21 at the terminal end of flexible assembly 22.

In one or more embodiments, the connector housing 20 comprises aflexible device enclosure 34 and a connector interlocking cap 32. Theflexible device enclosure 34 and the connector interlocking cap 32 servethe purpose of enclosing and sealing the terminal end of flexibleassembly 22 and also to provide environmental, EMI/EMC protection. Theconnector interlocking cap 32 can be made from a variety of materialssuch as, but not limited to, aluminum, titanium, steel and composites(conductive and non-conductive). The connector interlocking cap 32 isconfigured as the second half of the interlocking mechanism and isconfigured to couple with the receptacle interlocking mechanism 17.

The flexible device enclosure 34 and the connector interlocking cap 32may be configured as separate components or assembled to one anotherwith various mechanical retention elements such as, but not limited to,bolts, threaded studs and captive screws. As separate components, theinterlocking cap 32 fits over the flexible device enclosure andconfigured to lock onto receptacle interlocking element 17, asillustrated in FIG. 4.

As noted above, the connector housing 20 retains the terminal end of theflexible assembly 22, such that the flexible assembly 22 may benon-destructively removed from the enclosure 34. The connector housing20 is configured such that the flexible assembly electrical contacts 24at the terminal end of flexible assembly 22 are exposed to the receiverhousing electrical contacts 18 in order to make physical contact andbecome electrically interconnected with the receiver housing contacts 18in a non-permanent form when connector device 14 and the receiver 13 arecoupled together via connector interlocking cap 32 and receiverinterlocking member 17. Such non-permanent interconnection allows fordisengagement of the flexible assembly electrical contacts 24 from thereceiver housing electrical contacts 18 without causing damage to eitherthe flexible assembly electrical contacts 24 or to the receiver housingelectrical contacts 18.

In one or more embodiments, the connector device 14 further comprises acompression grommet 30 constructed of silicon or other compressive andnon-conductive material. The compression grommet 30 provides support forflexible assembly 22 inside of the connector device 14 and dampensmovement when the connector device 14 is subject to vibration.

In one or more embodiments, the connector device 14 further comprises aflexible assembly retention component 40 which securely retains theflexible assembly 22 within the connector device 14.

One or more embodiments of connector device 14 may further compriseactive and passive accessories and components, such as signal filters,signal indicators and power regulators. The connector device 14 mayfurther incorporate design features, such as “scoop-proof” components orkeying features to ensure proper alignment of conductive elements 18 and24.

The flexible assembly 22 can comprise an optional sealing grommet (notshown) to seal the flexible assembly within the connector housing. Suchsealing grommet provides a sealing interface between the flexibleassembly 22 and the connector housing 20.

The connector device 14 is configured to be reversibly couplable to thereceiver 13, such that each of the receiver housing electrical contacts18 is electrically connected to a flexible assembly electrical contact24 in a removable, non-permanent manner. Thus, all electrical contacts18 and 24 may be both serviceable and solderless. Each receiver housingelectrical contact 18 is mated to a flexible assembly electrical contact24 by one of several solderless connection methods known in the art,including, but not limited to, pin-socket mating systems; spring probesystems and compressive contact systems. In the embodiment illustratedin FIG. 4, each receiver housing electrical contact 18 is mated to acorresponding flexible assembly electrical contact 24 at a conductiveelement engagement surface 26.

The connector housing 20 is used as a structural member and as supportfor the flexible assembly 22, as well as for vibration dampeningpurposes. The connector housing 20 can be made from a multitude ofmaterials, including but not limited to the following: aluminum,titanium, steel, plastic, Polyether ether ketone (PEEK), as well ascomposites (conductive or non-conductive). The shape of the connectorhousing 20 can be circular, rectangular, as well as other shapes. Theconnector housing 20 can have multiple entry locations for a pluralityof flexible assemblies 22.

The electrical assembly combination 10 facilitates the installation andreplacement of a flexible assembly 22 to a rigid assembly 12 without theuse of solder or other permanent connection methods. Furthermore, theelectrical assembly combination of the invention 10 is configured suchthat the flexible assembly 22 and the rigid assembly 12 do not becomedisengaged during operation of the combination in environments thatwould otherwise cause disengagement, thereby making the electricalassembly combination useful in extreme environments. The several sets ofmated electrical contacts 18 and 24 may be individually disconnectedfrom each other at a conductive element engagement surface 26 withoutcausing damages to any of the contacts 18 and 24, and any contact 18 and24 may be removed from its respective retention structure withoutcausing damages to the contact 18 and 24 or to the retention structure.

While the invention herein disclosed has been described by means ofspecific embodiments and applications thereof, numerous modificationsand variations could be made thereto by those skilled in the art withoutdeparting from the scope of the invention set forth in the claims.

What is claimed is:
 1. An electrical assembly combination comprising: areceiver comprising a receiver housing, wherein said receiver housingcomprises a first end and a second end and a plurality of receiverhousing electrical contacts, wherein said first end of said receiverhousing mechanically couples to a rigid assembly with a plurality ofrigid assembly electrical contacts such that each one of said pluralityof receiver housing electrical contacts is electrically coupled to acorresponding one of said plurality of rigid assembly electricalcontacts; and a connector comprising a connector housing with aconnector interlocking cap and a compression grommet inside saidconnector housing, wherein said connector interlocking cap removablycouples directly to said second end of said receiver housing therebyforming an interlocking mechanism, wherein said connector housingsecurely retains a terminal end of a flexible assembly with saidcompression grommet between said terminal end and a top wall of saidinside of said connector housing, wherein each one of said plurality ofreceiver housing electrical contacts mates inside said receiver housingby a solderless connection to a corresponding one of a plurality offlexible assembly electrical contacts at said terminal end within anenclosure formed when said connector with said flexible assembly iscoupled to said receiver housing.
 2. The electrical assembly combinationof claim 1, wherein said receiver housing comprises a receiverinterlocking member at said second end.
 3. The electrical assemblycombination of claim 2, wherein said connector interlocking cap and saidreceiver interlocking member couple through a twist-to-lock mechanism.4. The electrical assembly combination of claim 1, wherein saidsolderless connection comprises a pin-socket mating system.
 5. Theelectrical assembly combination of claim 1, wherein said solderlessconnection comprises a spring probe system.
 6. The electrical assemblycombination of claim 1, wherein said solderless connection comprises acompressive contact system.
 7. The electrical assembly combination ofclaim 1, wherein said connector further comprises a flexible assemblyretention component that securely holds the flexible assembly terminalwithin the connector housing, wherein said flexible assembly retentioncomponent fits around a perimeter of said terminal end of said flexibleassembly.
 8. The electrical assembly combination of claim 1, whereinsaid connector further comprises a flexible device enclosure inside saidconnector interlocking cap for enclosing and sealing said terminal endof said flexible assembly inside said connector.
 9. The electricalassembly combination of claim 1, wherein said receiver further comprisesan insulator assembly to electrically isolate each one of said pluralityof receiver housing electrical contacts from each other.
 10. Anelectrical assembly combination comprising: a receiver comprising areceiver housing, wherein said receiver housing comprises a first endand a second end and a plurality of receiver housing electricalcontacts, wherein said first end of said receiver housing mechanicallycouples to a rigid assembly with a plurality of rigid assemblyelectrical contacts such that each one of said plurality of receiverhousing electrical contacts is electrically coupled to a correspondingone of said plurality of rigid assembly electrical contacts, whereinsaid receiver housing further comprises a receiver interlocking memberat said second end; and a connector comprising a connector housing witha connector interlocking cap and a compression grommet inside saidconnector housing, wherein said connector interlocking cap removablycouples directly to said receiver interlocking member thereby forming aninterlocking mechanism, wherein said connector housing securely retainsa terminal end of a flexible assembly such that said compression grommetis between said terminal end and a top wall of said inside of saidconnector housing, said terminal end comprising a plurality of flexibleassembly electrical contacts, wherein each one of said plurality ofreceiver housing electrical contacts mates inside said receiver housingby a solderless connection to a corresponding one of a plurality offlexible assembly electrical contacts at said terminal end within anenclosure formed when said connector with said flexible assembly iscoupled to said receiver housing.
 11. The electrical assemblycombination of claim 10, wherein said solderless connection is bycompressive contact.
 12. The electrical assembly combination of claim10, wherein said connector further comprises a flexible assemblyretention component that securely holds the flexible assembly terminalwithin the connector.
 13. The electrical assembly combination of claim10, wherein said connector further comprises a flexible device enclosureinside said connector interlocking cap for enclosing and sealing saidterminal end of said flexible assembly inside said connector.
 14. Theelectrical assembly combination of claim 10, wherein said receiverfurther comprises an insulator assembly to electrically isolate each oneof said plurality of receiver housing electrical contacts from eachother.
 15. The electrical assembly combination of claim 10, wherein saidconnector interlocking cap and said receiver interlocking member couplethrough a twist-to-lock mechanism.
 16. An electrical assembly connectorcomprising: a connector interlocking cap; a flexible device enclosurepartially inside said connector interlocking cap; and a compressiongrommet inside said flexible device enclosure, wherein said connectorinterlocking cap directly couples to an interlocking member of areceiver to form a twist-to-lock mechanism thereby securing saidflexible device enclosure within said connector interlocking cap andsaid receiver, wherein said compression grommet is between a terminalend of a flexible assembly located within said flexible device enclosureand a top wall of said inside of said flexible device enclosure, saidterminal end comprising a plurality of flexible assembly electricalcontacts, wherein each one of said plurality of flexible assemblyelectrical contacts mates within said receiver to a corresponding one ofa plurality of receiver housing electrical contacts within said receiverby a solderless connection method selected from a group consisting ofpin-socket mating system, spring probe system and compressive contactsystem when said connector with said flexible assembly is coupled tosaid receiver housing.
 17. The electrical assembly connector of claim16, wherein an opposing end to said receiver interlocking membermechanically couples to a rigid assembly with a plurality of rigidassembly electrical contacts such that each one of said plurality ofrigid assembly electrical contacts is electrically coupled to acorresponding one of said plurality of receiver housing electricalcontacts.
 18. The electrical assembly connector of claim 16, whereinsaid connector further comprises a flexible assembly retention componentto securely retain the flexible assembly terminal within the connector.19. The electrical assembly connector of claim 16, wherein saidconnector further comprises a sealing grommet to protect said terminalend of said flexible assembly inside said connector.
 20. The electricalassembly connector of claim 16, wherein said receiver further comprisesan insulator assembly to electrically isolate one receiver housingelectrical contact from another receiver housing electrical contact.